Carbon impregnation of porous ducting for evaporative emissions absorption

ABSTRACT

The present invention discloses a hydrocarbon-removing component for the air intake system of an internal combustion engine which removes hydrocarbons escaping a vehicle when the engine is not in use. The hydrocarbon-removing component of the present invention includes a duct with a hydrocarbon-removing material incorporated in an inner surface. The preferred hydrocarbon-removing material include activated carbon and zeolites.

BACKGROUND OF INVENTION

[0001] 1. Field of the Invention

[0002] The present invention is related to vehicle air intake componentsand, more particularly, to air intake components that removehydrocarbons from an air intake system when the vehicle engine is not inoperation.

[0003] 2. Background Art

[0004] Evaporative emission regulations that vehicles require thecontrol of polluting substances (primarily hydrocarbons) from thevehicle as it sits unused. These emissions are leaked out of the vehiclefrom many sources including the air intake system. In the past, onlythose from the fuel tank were captured, with carbon-filled canisters,but this has now been expanded to the entire vehicle. Newer regulationsrequire control of emission of harmful substances from the air inletsystem of the powertrain when the vehicle is at rest (not in use). Thesesubstances need to be retained within the air inlet system until thepowertrain is again used when the retention system will give up theharmful substances to be consumed and controlled through the normalexhaust emission control systems.

[0005] There are several ways to control the outward flow of pollutantsfrom the air intake system of an automobile. One such technique is thecareful shaping of the ducting and filter box. However, this method isoften not sufficient to meet the regulatory requirements. Accordingly,other methods must be used such as the incorporation of systems in theair intake system that use some form of carbon or other material toabsorb the pollutants during the rest cycle. When the vehicle is nextstarted, the in-rushing air will draw the pollutants from the absorbentand deal with them through the normal exhaust system pollution controls.This inward air rush also regenerates the absorption systems so thatthey may be reused. Unfortunately, these extra absorption systems addcost, weight and complexity to a vehicle and often restrict the airflow.

[0006] Many vehicles, especially with smaller engines, use an air intakesystem for the powertrain which uses in part a porous material for noiseattenuation. Most often, this is on the “dirty” side before the airreaches the air intake filter. Sometimes the porous material is usedafter the filter with a wrapping to keep dirty air from being drawn inthrough the pours from outside. However, such noise attenuation does notremove pollutants from a vehicle air intake system to any significantdegree.

[0007] For the reasons set forth above, there is a need for an improvedair intake system that removes pollutants when a vehicle is not in usethat does not significantly add cost, weight or complexity to thevehicle design.

SUMMARY OF INVENTION

[0008] The present invention overcomes the problems encountered in theprior art by providing a hydrocarbon-removing component for a vehicleair intake system of an internal combustion engine that comprises a ducthaving an inner surface and a cross-section and a hydrocarbon-removingmaterial incorporated into the inner surface of the duct. Thecross-section is of sufficient size to allow air to flow into theinternal combustion engine during operation. Accordingly, the componentof the present invention removes hydrocarbons when exposed to the air inthe vehicle air intake system when the internal combustion engine is notin use.

[0009] The hydrocarbon-removing component of the present invention isadvantageously integrating the hydrocarbon-removing material into anexisting air intake component. Such components include the air inlet,the air filter, the resonator, and the clean air tube. For example, if avehicle uses a porous duct for the control of noise, whether before orafter the air filter, the porous duct can be coated or impregnated withcarbon or similar material to absorb pollutants. This takes advantage ofthe great surface area of the porous ducting to increase the absorptioncapabilities of the duct. Thus a preexisting part with slight andinexpensive modifications can be made to serve two functions andeliminate the need for the addition of a separate absorption device.Alternatively, if the vehicle still requires an absorption device tomeet emission regulations, by coating or impregnating the porous ductwith carbon or other absorption materials, the absorption device can bemade smaller, less expensive and less restrictive by the inexpensiveaddition of an absorbing material to a device which is already in placefor noise attenuation. If the porous duct is on the “dirty” inlet side,it can be encased in a solid wall duct or sleeve to keep the pollutantsfrom escaping through the duct walls into the environment. The porousmaterial is typically made from a natural or synthetic fiber which iswoven, spun or otherwise formed into the duct.

[0010] In another embodiment of the present invention, a method offorming the hydrocarbon-removing component of the present invention isprovided. This method comprises adhering a hydrocarbon-removing materialto the inner surface of a section of an air intake component with anadhesive capable of withstanding temperatures from −40 to 300 degrees F.

[0011] In yet another embodiment of the present invention, a secondmethod of forming the hydrocarbon-removing component of the presentinvention is provided. This second method comprises combining fibers, ahydrocarbon-removing material, and a binder together to form a premix.The premix is then pressed together to form a sheet which is cut into apattern that can be formed into a duct.

BRIEF DESCRIPTION OF DRAWINGS

[0012]FIG. 1 is a schematic of an air intake system illustratingsections that may incorporate the air intake component of the presentinvention.

DETAILED DESCRIPTION

[0013] Reference will now be made in detail to presently preferredcompositions or embodiments and methods of the invention, whichconstitute the best modes of practicing the invention presently known tothe inventors.

[0014] In an embodiment of the present invention, a hydrocarbon-removingcomponent for a vehicle air intake system of an internal combustionengine is provided. The hydrocarbon-removing component comprises a ducthaving an inner surface and a cross-section, and a hydrocarbon-removingmaterial. The cross-section is of sufficient size to allow air to flowinto the internal combustion engine during operation. In a typicalapplication of the present invention, the duct is a flexible tube with agenerally circular cross-section of 2 to 6 inch diameter. The duct willalso have another surface which does not come into direct contact withthe air drawn into a vehicle intake system. Furthermore, thehydrocarbon-removing material is incorporated into the inner surface ofthe duct by either being impregnated into the duct or adhered to theinner surface. Accordingly, when the hydrocarbon-removing component ofthe present invention is used in an air intake system, hydrocarbons areremoved from the air intake when the vehicle is not in operation. Thesecondary purpose is to absorb noise created in the intake process.

[0015] Though not limiting the present invention to any particularmechanism of operation, the hydrocarbon-removing material removes thehydrocarbons in the vehicle air intake system by adsorption, absorption,or by a combination of adsorption and absorption. Furthermore, thehydrocarbon-removing material must be able to withstand the standardunder-hood automotive environment. For example, this material must beable to tolerate temperature ranges of −40 to +300 degrees F.; it mustbe resistant to water, coolant, oil, gasoline, diesel fuel, brake fluid,salt, and any other common automobile substances. Also the materialsmust withstand all vibration and air flow stresses that a givenpowertrain might demand. Preferred hydrocarbon-removing materialsinclude activated carbon, zeolites, or mixtures thereof. Activatedcarbon or charcoal is an amorphous form of carbon that is characterizedby having a porous internal microstructure having an extremely highsurface area. Charcoal becomes activated by heating it with steam in theabsence of oxygen. Activated carbon tends to have large pores. Zeolites,on the other hand, contain very small internal pores, in all cases from3 to 5 angstroms. For this reason, zeolite is a highly selectiveadsorbent of specific gas-phase molecules and elements. Many of theidentified indoor air pollutants, including formaldehyde, chloroform,ammonia and carbon monoxide, are in a size range that is mosteffectively sieved by zeolite.

[0016] The term “duct” are used herein refers to any section of avehicle air intake section that air may flow into. Such sections includethe air inlet, the air filter, the resonator, and the clean air tube. Ina particularly preferred embodiment, the duct will be corrugated. Theduct used in the present invention may be made of any material that canwithstand under the hood environment. Furthermore, to maximize thecarbon holding capacity and the sound adsorption capacity, the ductshould have as much surface area as possible. This includes not onlyfolds or other features to increase surface area but also pores,crevices, loops, cilia, etc., that are part of the material from whichthe duct is made. The actual material used would be based on acombination of sound-absorbing ability, carbon-holding capacity, andmanufacturing and cost considerations. While there are numerousmaterials which can meet these criteria, a woven or matted nylon orpolyester strip wound into a tube or other shape seems most appropriateand cost effective. Suitable materials of construction include plastic,paper, or cardboard. More preferably, the duct is formed from athermoplastic polymer. Suitable thermoplastic polymers includepolyolefin-based polymers, polystyrene-based polymers, polycabonatepolymers, or mixture thereof. Most preferably, the duct is made frompolyethylene, polypropylene, polyester, or nylon.

[0017] With reference to FIG. 1, a schematic of a vehicle air intakesystem is provided. Air intake system 2 comprises intake manifold 4attached to engine 6. Intake manifold 4 is connected to throttle body 10which, in turn, is connected to clean air tube 12. Resonator 14 connectsto clean air tube 12 and is used to attenuate engine sound. Clean airtube 12 also connects to mass air meter 16 which is located downstream(as measure from the outside to the inside) from air filter 18. Airinlet 20 is located, in turn, further upstream from air filter 18.During normal engine operation, air is drawn into air intake 20 and theninto air filter 18 where particles and other contaminants are removed.The clean air then flows through mass air meter 16 through clean airtube 12 and then into the engine 6 through intake manifold 4. Thehydrocarbon-removing component of the present invention isadvantageously integrated into any part of the air intake system asdescribed in more detail below. For example, the hydrocarbon-removingcomponent may be part of clean air tube 12, resonator 14, air filter 18,or air intake 20.

[0018] The hydrocarbon-removing component of the present invention ismade by several techniques know to those in the art of duct making. Forexample, the hydrocarbon material may be vibrated or rubbed into theweave of a duct made of a woven material. In one preferred method, ahydrocarbon-removing material is adhered to the inner surface of a duct.The duct is preferably made of materials as set forth above. Suitableducts are those which may also be simultaneously used to attenuate soundfrom the automobile engine. Such ducts include, but are not limited to,the Sonoflex Line of ducts commercially available from Westaflex Brasilor from West Akron North America located in Akron, Ohio. Alternatively,the duct may be any other duct used in the air intake system such as theTermoflex and Flex lines of ducts also available from Westaflex Brasilor West Akron North American. As set forth above, the cross-section isof sufficient size to allow air to flow into the internal combustionengine during operation. Typically, such ducting will have across-section from about 2 inches to about 6 inches. Accordingly, whenthe hydrocarbon-removing component of the present invention is used inan air intake system, hydrocarbons are removed from the air intake whenthe vehicle is not in operation. The hydrocarbon-removing material isadhered to the inner-surface of the duct by applying an adhesive to theinner surface of the duct to form a coated inner surface and thenapplying the hydrocarbon-removing material to the coated inner surface.The adhesive used must be sufficiently chemically resistant so that itdoes not degrade when exposed to the engine environment. Furthermore,the adhesive must be able to withstand temperatures from −40 to 300degrees F. Suitable adhesives include, but are not limited to, PVCthermosetting adhesives such as Microset-30 commercially available fromNavtara Organics Limited. The preferred hydrocarbon-removing material isactivated carbon or a zeolite as set forth above.

[0019] In another embodiment of the present invention, thehydrocarbon-removing component of the present invention is made bycombining fibers, a hydrocarbon-removing material, and a binder togetherto form a premix. The premix is then pressed together to form a sheet.The sheet is then cut into a pattern that may be rolled into a duct.Curing of the premix is optionally accelerated by heating. Preferredfibers include plastic, paper or cardboard fibers. More preferably, thefibers are thermoplastic polymer fibers. Suitable thermoplastic polymerfibers include polyolefin-based fibers, polystyrene-based fibers,polycabonate fibers, or mixture thereof. Most preferably, the fibers arepolyethylene fibers, polypropylene fibers, polyester fibers, or nylonfibers. The binder is also selected from material that can withstand theautomobile under the hood environment. Suitable binders includepolyvinyl acetate, polyvinyl chloride homopolymers, polyvinylchloride-polyvinyl acetate copolymers, vinyl chloride propylenecopolymer, polyvinyl chloride-acrylic copolymers, and mixtures thereof.The preferred hydrocarbon-removing material is the same as set forthabove.

[0020] In yet another embodiment of the present invention, the componentof the present invention is made by lining the interior of a duct orother component of the air intake system with a sheet impregnated withthe hydrocarbon-removing material. Alternatively, the sheet is firstformed into a tube which can be slipped into an air intake component.Preferably, such sheet will be foamed to provide a high surface area.Suitable foamed sheets are available include the Nanosorb™ Adsorptivefilter commercially available from Mann & Hummel. The sheet is eitherattached or adhered to the inner surface of a duct or any othercomponent in the air intake system. Again, the adhesive used must besufficiently chemically resistant so that it does not degrade whenexposed to the engine environment and must be able to withstandtemperatures from −40 to 300 degrees F. Suitable adhesives include, butare not limited to, PVC thermosetting adhesives such as Microset-30commercially available from Navtara Organics Limited. Alternatively, thesheet is attached by a physical mechanism such as bolting or stapling.

[0021] While embodiments of the invention have been illustrated anddescribed, it is not intended that these embodiments illustrate anddescribe all possible forms of the invention. Rather, the words used inthe specification are words of description rather than limitation, andit is understood that various changes may be made without departing fromthe spirit and scope of the invention.

1. A hydrocarbon-removing component for a vehicle air intake system ofan internal combustion engine, the component comprising: a duct havingan inner surface and a cross-section, the cross-section being ofsufficient size to allow air to flow into the internal combustion engineduring operation; and a hydrocarbon-removing material; wherein thehydrocarbon-removing material is incorporated into the inner surface ofthe duct and removes hydrocarbons when exposed to the air in the vehicleair intake system when the internal combustion engine is not in use. 2.The component of claim 1 wherein the duct is part of an air filter. 3.The component of claim 1 wherein the duct is part of a resonator.
 4. Thecomponent of claim 1 wherein the hydrocarbon-removing material removesthe hydrocarbons in the vehicle air intake system by adsorption,absorption, or by a combination of adsorption and absorption.
 5. Thecomponent of claim 1 wherein the hydrocarbon-removing material isactivated carbon or a zeolite.
 6. The component of claim 1 wherein thecross-section is essentially circular with a diameter of 2 to 6 inches.7. The component of claim 1 wherein the hydrocarbon-removing material isaffixed to the inner surface of the duct with an adhesive.
 8. Thecomponent of claim 1 wherein the hydrocarbon-absorbing material isaffixed to the inner surface of the duct with an adhesive.
 9. Thecomponent of claim 1 wherein the hydrocarbon-removing material iscombined with plastic fibers and a binder to form the duct.
 10. Thecomponent of claim 1 wherein the hydrocarbon-absorbing material iscombined with plastic fibers and a binder that are used to form theduct.
 11. The component of claim 1 wherein the duct is formed fromplastic, paper or cardboard.
 12. The air intake component of claim 1wherein the duct formed from a thermoplastic polymer.
 13. The air intakecomponent of claim 1 wherein the thermoplastic polymer is apolyolefin-based polymer, a polystyrene-based polymer, a polycabonatepolymer, or mixture thereof.
 14. The air intake component of claim 1wherein the duct is made from polyethylene, polypropylene or nylon. 15.A hydrocarbon-removing component for a vehicle air intake system of aninternal combustion engine, the component comprising: a duct having aninner surface and a cross-section, the cross-section being of sufficientsize to allow air to flow into the internal combustion engine duringoperation; and a sheet impregnated with hydrocarbon-removing material;wherein the sheet impregnated hydrocarbon-removing material is attachedto the inner surface of the duct and removes hydrocarbons when exposedto the air in the vehicle air intake system when the internal combustionengine is not in use.
 16. The air intake component of claim 15 whereinthe sheet impregnated hydrocarbon-removing material is attached to theinner surface of the duct with an adhesive.
 17. The air intake componentof claim 15 wherein the sheet impregnated hydrocarbon-removing materialis formed into a tube that is slipped into the duct.
 18. A method ofmaking a component for removing hydrocarbons from a vehicle air intakesystem of an internal combustion engine, the method comprising:providing a duct having an inner surface and a cross-section, thecross-section being of sufficient size to allow air to flow into theinternal combustion engine during operation; and adhering ahydrocarbon-removing material to the duct, wherein the component isuseable in the vehicle air intake system to remove hydrocarbons from theair intake system while the internal combustion engine in not inoperation.
 19. The method of claim 18 wherein the step of adhering ahydrocarbon-removing material comprises applying an adhesive to theinner surface of the duct to form a coated inner surface; and applyingthe hydrocarbon-removing material to the coated inner surface.
 20. Themethod of claim 18 wherein the hydrocarbon-removing material isactivated carbon or a zeolite.
 21. The method of claim 18 wherein theduct is made of plastic, paper, or cardboard.
 22. The method of claim 18wherein the duct is made from a thermoplastic polymer selected from thegroup consisting of polyolefin-based polymer, a polystyrene-basedpolymer, a polycabonate polymer, nylon, or mixtures thereof.
 23. Amethod of making a component for removing hydrocarbons from a vehicleair intake system of an internal combustion engine, the methodcomprising: combining fibers, a hydrocarbon-removing material, and abinder together to form a premix; pressing the premix together to form asheet; cutting the sheet into a pattern rollable into a duct; androlling the sheet into a duct.
 24. The method of claim 23 wherein thepre-mix is heated during the step of pressing the premix together. 25.The method of claim 23 wherein the hydrocarbon-removing material isactivated carbon or a zeolite.
 26. The method of claim 23 wherein thefibers are plastic or paper fibers.
 27. The method of claim 23 whereinthe fibers are thermoplastic fibers selected from the group consistingof polyolefin-based fibers, polystyrene-based fibers, polycabonatefibers, or mixture thereof.
 28. The method of claim 23 wherein thefibers are polyethylene fibers, polypropylene fibers, polyester fibers,or nylon fibers.
 29. A method of making a component for removinghydrocarbons from a vehicle air intake system of an internal combustionengine, the method comprising: providing a duct having an inner surfaceand a cross-section, the cross-section being of sufficient size to allowair to flow into the internal combustion engine during operation; andattaching a sheet impregnated with a hydrocarbon-removing material tothe duct, wherein the component is useable in the vehicle air intakesystem to remove hydrocarbons from the air intake system while theinternal combustion engine in not in operation.
 30. The method of claim29 wherein the sheet impregnated with a hydrocarbon-removing material isattached to the duct with an adhesive.